EP1778457B1 - Method of making water-resistant gypsum-based article - Google Patents
Method of making water-resistant gypsum-based article Download PDFInfo
- Publication number
- EP1778457B1 EP1778457B1 EP05781059.0A EP05781059A EP1778457B1 EP 1778457 B1 EP1778457 B1 EP 1778457B1 EP 05781059 A EP05781059 A EP 05781059A EP 1778457 B1 EP1778457 B1 EP 1778457B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- siloxane
- water
- gypsum
- magnesium oxide
- weight
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 229910052602 gypsum Inorganic materials 0.000 title claims description 101
- 239000010440 gypsum Substances 0.000 title claims description 101
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title claims description 97
- 238000004519 manufacturing process Methods 0.000 title description 13
- KPUWHANPEXNPJT-UHFFFAOYSA-N disiloxane Chemical class [SiH3]O[SiH3] KPUWHANPEXNPJT-UHFFFAOYSA-N 0.000 claims description 83
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 46
- 239000000395 magnesium oxide Substances 0.000 claims description 41
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 40
- 239000002002 slurry Substances 0.000 claims description 38
- 239000000839 emulsion Substances 0.000 claims description 28
- 238000000034 method Methods 0.000 claims description 26
- 238000002156 mixing Methods 0.000 claims description 13
- 239000004615 ingredient Substances 0.000 claims description 12
- 239000012530 fluid Substances 0.000 claims description 9
- 239000000203 mixture Substances 0.000 claims description 9
- 239000003995 emulsifying agent Substances 0.000 claims description 6
- 125000004122 cyclic group Chemical group 0.000 claims description 2
- 238000007493 shaping process Methods 0.000 claims description 2
- 229920001843 polymethylhydrosiloxane Polymers 0.000 claims 3
- 235000012245 magnesium oxide Nutrition 0.000 description 41
- 239000000047 product Substances 0.000 description 22
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical group [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 16
- 239000003054 catalyst Substances 0.000 description 16
- 239000000463 material Substances 0.000 description 11
- 238000006243 chemical reaction Methods 0.000 description 8
- -1 siloxanes Chemical class 0.000 description 8
- 238000010521 absorption reaction Methods 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- 239000000758 substrate Substances 0.000 description 6
- 229910052925 anhydrite Inorganic materials 0.000 description 4
- 239000011162 core material Substances 0.000 description 4
- 239000006260 foam Substances 0.000 description 4
- 229910052739 hydrogen Inorganic materials 0.000 description 4
- 239000001257 hydrogen Substances 0.000 description 4
- 239000005871 repellent Substances 0.000 description 4
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 3
- 229920002472 Starch Polymers 0.000 description 3
- 229910000287 alkaline earth metal oxide Inorganic materials 0.000 description 3
- ZOMBKNNSYQHRCA-UHFFFAOYSA-J calcium sulfate hemihydrate Chemical compound O.[Ca+2].[Ca+2].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O ZOMBKNNSYQHRCA-UHFFFAOYSA-J 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 239000004088 foaming agent Substances 0.000 description 3
- 230000036571 hydration Effects 0.000 description 3
- 238000006703 hydration reaction Methods 0.000 description 3
- 150000004679 hydroxides Chemical class 0.000 description 3
- 239000011505 plaster Substances 0.000 description 3
- 229920001296 polysiloxane Polymers 0.000 description 3
- 229920002050 silicone resin Polymers 0.000 description 3
- 235000019698 starch Nutrition 0.000 description 3
- 239000008107 starch Substances 0.000 description 3
- 239000000654 additive Substances 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 239000002270 dispersing agent Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000010348 incorporation Methods 0.000 description 2
- 239000003112 inhibitor Substances 0.000 description 2
- 239000007764 o/w emulsion Substances 0.000 description 2
- 238000006116 polymerization reaction Methods 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- UGTZMIPZNRIWHX-UHFFFAOYSA-K sodium trimetaphosphate Chemical compound [Na+].[Na+].[Na+].[O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1 UGTZMIPZNRIWHX-UHFFFAOYSA-K 0.000 description 2
- IJJWOSAXNHWBPR-HUBLWGQQSA-N 5-[(3as,4s,6ar)-2-oxo-1,3,3a,4,6,6a-hexahydrothieno[3,4-d]imidazol-4-yl]-n-(6-hydrazinyl-6-oxohexyl)pentanamide Chemical compound N1C(=O)N[C@@H]2[C@H](CCCCC(=O)NCCCCCC(=O)NN)SC[C@@H]21 IJJWOSAXNHWBPR-HUBLWGQQSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- WQZGKKKJIJFFOK-GASJEMHNSA-N Glucose Natural products OC[C@H]1OC(O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-GASJEMHNSA-N 0.000 description 1
- 101000628535 Homo sapiens Metalloreductase STEAP2 Proteins 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 102100026711 Metalloreductase STEAP2 Human genes 0.000 description 1
- 229920006328 Styrofoam Polymers 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 125000000217 alkyl group Chemical group 0.000 description 1
- 239000006265 aqueous foam Substances 0.000 description 1
- 239000010426 asphalt Substances 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000002738 chelating agent Substances 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000011436 cob Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 239000008121 dextrose Substances 0.000 description 1
- 239000010881 fly ash Substances 0.000 description 1
- XLYOFNOQVPJJNP-ZSJDYOACSA-N heavy water Substances [2H]O[2H] XLYOFNOQVPJJNP-ZSJDYOACSA-N 0.000 description 1
- 150000004677 hydrates Chemical class 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000009533 lab test Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- 230000002906 microbiologic effect Effects 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 235000010755 mineral Nutrition 0.000 description 1
- 239000012768 molten material Substances 0.000 description 1
- PSZYNBSKGUBXEH-UHFFFAOYSA-M naphthalene-1-sulfonate Chemical compound C1=CC=C2C(S(=O)(=O)[O-])=CC=CC2=C1 PSZYNBSKGUBXEH-UHFFFAOYSA-M 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- LQPLDXQVILYOOL-UHFFFAOYSA-I pentasodium;2-[bis[2-[bis(carboxylatomethyl)amino]ethyl]amino]acetate Chemical compound [Na+].[Na+].[Na+].[Na+].[Na+].[O-]C(=O)CN(CC([O-])=O)CCN(CC(=O)[O-])CCN(CC([O-])=O)CC([O-])=O LQPLDXQVILYOOL-UHFFFAOYSA-I 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 238000002407 reforming Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- SCPYDCQAZCOKTP-UHFFFAOYSA-N silanol Chemical compound [SiH3]O SCPYDCQAZCOKTP-UHFFFAOYSA-N 0.000 description 1
- 229920002545 silicone oil Polymers 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000008261 styrofoam Substances 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
- 239000002982 water resistant material Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
- C04B40/0028—Aspects relating to the mixing step of the mortar preparation
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/26—Carbonates
- C04B14/28—Carbonates of calcium
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/30—Oxides other than silica
- C04B14/304—Magnesia
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
- C04B24/40—Compounds containing silicon, titanium or zirconium or other organo-metallic compounds; Organo-clays; Organo-inorganic complexes
- C04B24/42—Organo-silicon compounds
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/03—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on magnesium oxide, calcium oxide or oxide mixtures derived from dolomite
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
- C04B40/0028—Aspects relating to the mixing step of the mortar preparation
- C04B40/0039—Premixtures of ingredients
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/27—Water resistance, i.e. waterproof or water-repellent materials
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/23—Sheet including cover or casing
- Y10T428/232—Encased layer derived from inorganic settable ingredient
Definitions
- the present invention relates to a method of making moisture resistant gypsum-based products, e.g. gypsum boards, reinforced gypsum composite boards, plasters, machinable materials, joint treatment materials, and acoustical tiles, by adding a small amount of a siloxane to the aqueous slurry used to make the gypsum-based product. More particularly, the present invention relates to the addition of a small amount of a dead burned magnesium oxide catalyst to the aqueous slurry to enhance the curing of the siloxane.
- Gypsum is a naturally occurring mineral which is typically found in old salt-lake beds, volcanic deposits and clay beds.
- gypsum is calcium sulfate dihydrate (CaSO 4 2H 2 O). This material is produced also as a by-product in various industrial processes.
- Calcined gypsum refers to both the hemihydrate and anhydrite forms of calcium sulfate. Calcined gypsum is capable of reacting with water to form calcium sulfate dihydrate which is a fairly hard and rigid product and which is referred to herein as "set gypsum.”
- gypsum board which is widely used as a structural building panel.
- gypsum board comprises a core made from an aqueous slurry of calcined gypsum which hydrates to form set gypsum.
- the board has a paper sheet lining adhered to both of its faces.
- a characteristic of set gypsum is that it has a tendency to absorb water.
- a gypsum core containing no water-resistant additives can absorb as much as 40 to 50 wt. % water when immersed therein at a temperature, of 21,11°C (70°F) for about two hours. In applications where the gypsum product is exposed to water or high humidity, this characteristic is undesirable.
- the absorption of water by the gypsum tends to reduce the strength of the product to render the product vulnerable to microbiological growth, and to cause the facings to delaminate.
- Gypsum board may be used also in bathrooms as an underlying surface which is covered with plastic or ceramic tile and for this purpose it is often referred to as a "tile-backing board.” In applications such as these, it is important that the gypsum board exhibit good water resistance.
- the present invention relates to an improved method of manufacturing water-resistant gypsum compositions which have incorporated therein a siloxane to impart water resistance to the set gypsum product.
- water resistant should be understood to mean the ability of a prefabricated structural element as defined above to limit the uptake of water by the plaster substrate, while still retaining the dimensional stability and mechanical integrity of the structural element in question.
- this water resistance is codified or regulated by specific standards.
- the ASTM 630/630M-96a and the ASTM 1398 standards require in particular that, when such a gypsum-base article is immersed in water for two hours, the water uptake by the plaster substrate is less than 5% and the water absorption on the surface (called the Cobb equivalent) is less than 1.60 g/m 2 .
- This water repellency is achieved by using any process comprising, in general, at least the following steps:
- siloxanes to make moisture resistant gypsum-based products, such as gypsum wall board, is well known.
- Generality a small amount of a siloxane is added to the aqueous slurry used to make the gypsum-based product and the product is formed and dried.
- the production of such moisture resistant gypsum-based products is described in US Patents 3.455,710 ; 4,643,711 ; 5,135,805 ; 5,330,762 ; 5,366,810 ; 5,626,605 ; 5,626,668 ; 6,100,607 and 6,569,541 among others.
- JP 9 1429185 A describes the production of a gypsum board by mixing gypsum, a siloxane and e.g. magnesium oxide. It has been found, however, that in some cases the siloxane used to make the gypsum-based product water resistant does not completely cure in a reasonable period of time or does not completely cure at all. In either case, the water resistance does not develop to a satisfactory level.
- the present invention relates to a method of making moisture resistant gypsum-based products, e.g., gypsum boards, reinforced gypsum composite boards, plasters, machinable materials, joint treatment materials, and acoustical tiles, according to claim 1.
- the method is among others characterized by adding to the aqueous slurry used to make the gypsum-based product a small amount of a siloxane and a catalyst to enhance the curing of the siloxane.
- the method comprises mixing a siloxane emulsion with the gauging water used to prepare said gypsum-based article; mixing a dead burned magnesium oxide catalyst with calcined gypsum; mixing the silicone/water mixture with the gypsum/magnesium oxide mixture to form an aqueous slurry; and shaping the slurry into the desired shape and allowing said shaped slurry to set to form a set gypsum-based, water-resistant article.
- the present invention contemplates the use of 0.4 to 1.0% of the siloxane, based on the weight of the calcined gypsum and other dry ingredients.
- a siloxane/water emulsion is formed by mixing the siloxane with a portion of the gauging water in a high intensity mixer for a few seconds.
- the catalyst is dead-burned magnesium oxide. 0.1 to 0.5 wt % of magnesium oxide is used, based on the weight of the gypsum.
- the invention further relates to a gypsum-containing board according to claim 10.
- gypsum-based structures such as wallboard
- a metered amount of water called, "gauging water”
- the calcined gypsum and the other dry ingredients used to make the wallboard are usually dry blended and then are continuously fed to the pin mixer where they are mixed with the gauging water for a few seconds to form an aqueous slurry.
- Foam used to reduce the wallboard density may also be added to the pin mixer.
- the slurry formed in the pin mixer is then shaped into the article, such as the wall board and then the shaped article is dried. In order to obtain the best water resistance, it is necessary to uniformly distribute the siloxane on the gypsum.
- the present invention broadly contemplates improving the water resistance of gypsum based article by adding a polymerizable siloxane in the form of a stable emulsion to the slurry used to make the gypsum based articles.
- the slurry is then shaped and dried under conditions which promote the polymerization of the siloxane to form a highly cross-linked silicone resin.
- a catalyst which promotes the polymerization of the siloxane to form a highly cross-linked silicone resin is added to the gypsum slurry.
- the siloxane is generally a fluid linear hydrogen-modified siloxane, but can also be a cyclic hydrogen-modified siloxane. Such siloxanes are capable of forming highly cross-linked silicone resins. Such fluids are well known to those of ordinary skill in the art and are commercially available and are described in the patent literature.
- the linear hydrogen modified siloxanes useful in the practice of he present invention comprise those of the general formula: RHSiO 2/2 wherein R represents a saturated or unsaturated mono-valent hydrocarbon radical. In the preferred embodiments, R represents an alkyl group and most preferably R is methyl.
- the siloxane emulsion is preferably added to the gauging water before the slurry is formed order to provide sufficient time for the siloxane emulsion to thoroughly mix with water used to form the slurry.
- siloxane emulsion It is essential that the siloxane emulsion be stable until it reaches the pin mixer and that it remains well dispersed under the conditions of the slurry. That is, the siloxane emulsion must remain well dispersed in the presence of the additives, such as accelerators, that are present in the slurry. The siloxane emulsion must remain stable through the steps in which the gypsum based articles are formed as well.
- the gypsum-based water resistant articles of the present invention are preferably made with a methyl hydrogen polysiloxane fluid sold under the name SILRES BS-94 by Wacker-Chemie GmbH as the siloxane.
- the manufacturer indicates this product is a siloxane fluid containing no water or solvents. It is contemplated that 0.3 to 1.0% of the BS-94 siloxane may be used, based on the weight of the dry ingredients. It is preferred to use from 0.4 to 0.8% of the siloxane.
- the present invention contemplates the use of a wide variety of siloxane emulsions to provide improved water resistance.
- a siloxane/water emulsion is formed by mixing a siloxane fluid with a small amount of water in a high intensity mixer for a few seconds. No chemical emulsifier is used. It has been found that this process produces an emulsion that is sufficiently stable that it can be mixed with the gauging water to distribute the siloxane uniformly throughout the gauging water.
- the siloxane/water emulsion enters the pin mixer and is mixed with the calcined gypsum and other dry materials to form the slurry.
- a portion of the gauging water is continuously stripped from the gauging water line and fed into a high intensity mixer.
- the required amount of a siloxane oil is continuously metered into the high intensity mixer where it is mixed with the gauging water for 1-2 seconds to form an oil-in-water emulsion.
- a ratio of about 25 parts of water may be mixed with each part of siloxane.
- the ratio of water to siloxane is not critical. It is preferred to use no chemical emulsifying agent because emulsifiers can adversely effect the gypsum rehydration reaction, the stability of foam added to the system and the adhesion of the paper facing to the gypsum core. It has been found that the siloxane/water emulsion formed sufficiently stable without any chemical emulsifier.
- Pre-made siloxane emulsions also may be used. However, pre-made siloxane emulsions frequently have stability problems during storage and the emulsifiers used with pre-made emulsions tend to cause problems in making the gypsum article, such as paper adhesion problems and problems in the gypsum rehydration process
- the siloxane/water emulsion formed in the high-intensity mixer is immediately mixed with the balance of the gauging water, which is then metered into the pin mixer.
- the siloxane/water emulsion is sufficiently stable that retains its characteristics as an emulsion as it enters the pin mixer. This procedure results in the siloxane being uniformly distributed throughout the aqueous gypsum slurry and uniformly distributed throughout the resulting gypsum-based article.
- the siloxane product described above is a hydrogen polysiloxane. It cures by forming a reactive silanol intermediate (OH compound) to yield polymethylsilicic acid. It is postulated that in order to develop the water resistance, it is necessary for the siloxane to cure within the wallboard. When the siloxane is added to the gypsum slurry, the curing reaction begins quite slowly. In many cases, the water-resistance of the wallboard made by the foregoing process does not develop for a week or two. In other cases, the water-resistance of the wallboard made by the foregoing process does not develop completely. When the siloxane cures slowly and the water-resistance does not develop immediately, the wallboard must be stored for a time sufficient for the water-resistance to develop before the board can be shipped.
- OH compound reactive silanol intermediate
- the catalyst is dead-burned magnesium oxide because it almost completely water insoluble and is non-reactive with the components of the slurry other than the siloxane.
- the dead burned magnesium oxide speeds up the curing of the siloxane and, in some cases, causes the siloxane to cure more completely.
- the dead burned magnesium oxide catalyzes the curing of the siloxane without causing magnesium commercially available with a consistent composition.
- the catalyst is a dry material that is dry-blended with the calcined gypsum and the other dry materials in order to uniformly distribute the catalyst throughout the calcined gypsum.
- the dry-mixture containing the catalyst is then added to the pin mixer.
- a relatively small amount of the catalyst may be used. It has been found that from 0.1 to 0.5% by weight of the dead burned magnesium oxide, based on the weight of the calcined gypsum, may be used. Preferably from 0.2 to 0.4% by weight of magnesium oxide based on the weight of the gypsum is used.
- the catalyst is dead-burned magnesium oxide sold under the name "Baymag 96" from “Baymag, Inc. of Calgary, Alberta, Canada. It has a surface area of at least 0.3 square meters per gram as measured by BET. It has a loss on ignition of less than 0.1% by weight.
- the difference between dead-burned magnesium oxide used in the present invention and conventional magnesium oxide can be demonstrated by comparing the increase in temperature when the respective materials are mixed with water.
- Rate of the exothermic reaction of dead-burned magnesium oxide (“Baymag 96) and conventional magnesium oxide (Baymag 30) in water was determined using Temperature Rise System (TRS).
- TRS Temperature Rise System
- the TRS unit is an electronic thermoster that measures the heat evolved from the exothermic reaction of MgO with water.
- Bach sample contained 50 grams magnesium oxide and 100 ml water, soaked 10 seconds and handmixed for 10 seconds.
- the thermoster is placed into a cup where the magnesium oxide and water mixture has been poured; this cup is in a quasi-temperature stable environment (Styrofoam container).
- the data is collected by a data acquisition system.
- the catalyst is dead-burned magnesium oxide sold under the name "Baymag 96" from “Baymag, Inc. because it produces a temperature rise of less than 0,55°C (1°F) in the Temperature Rise System.
- Magnesium oxides that produce a temperature rise of no more than about 1,1 °C (about 2°F) are suitable for use in the present invention.
- Magnesium oxides that produce greater temperature rises, such as the Baymag 30, provide adequate catalysis of the siloxane, but such magnesium oxides are not preferred because they retard of the gypsum rehydration process and cause loss of paper bonding.
- Paper-covered foamed gypsum boards were prepared on a typical full scale production line in a commercial gypsum board manufacturing facility.
- the ingredients and their approximate weight percentages are listed in Table 2.
- a portion of the gauging water is continuously stripped from the gauging water line and fed into a high intensity 30 mixer.
- the mixer was a Vertiflo Pump Co. Model No 1420-2x-2x8.
- the required amount of a siloxane fluid is continuously metered into the high intensity mixer where it is mixed with the gauging water for 1-2 seconds to form an oil-in-water emulsion in situ.
- a ratio of about 25 parts of water is mixed with each part of siloxane.
- the siloxane/water emulsion was then returned to the gauging water line where it mixed with the balance of the gauging water.
- the magnesium oxide was dry-blended with the calcined gypsum and other dry ingredients prior to the pin mixed. Except for the inclusion of siloxane and magnesium oxide in the preparation, the boards were prepared using methods and ingredients typical of prior art gypsum board production methods and ingredients. Boards were prepared with various concentrations of siloxane and various amounts of magnesium oxide and were compared with control boards and tested for water resistance in accordance with ASTM Test-1396.
- the accelerator is not heated during its preparation;
- the starch was dry-milled acid-modified HI-BOND starch obtained commercially from Lauhoff Grain Co.;
- the dispersant was DILOFLO, a naphthalene sulfonate obtained commercially from GEO Specialty Chemicals of Ambler, Pennsylvania;
- the paper fiber was fine hammer milled paper fiber;
- the set retarder was VERSENEX 80, a chelating agent obtained commercially from Van Walters & Rogers of Kirkland, Washington;
- the foaming agent was WITCOLATE1276, obtained commercially from Witco Corp. of Greenwich, Conn.;
- the sodium trimetaphosphate was supplied commercially by Astaras Co. of St.
- the recalcination inhibitor was CERBLOSE 2001, a dextrose employed to reduce recalcination of board ends during drying.
- the siloxane was a fluid sold under the name SILRES BS-94 by Wacker-Chemie GmbH.
- the magnesium oxide was a dead-burned magnesium oxide sold under the name "Baymag 96" from Baymag, Inc. of Calgary, Alberta, Canada.
- the boards were produced on a four foot wide continuous production line by: continuously introducing and mixing the ingredients in a mixer to form an aqueous slurry (the foaming agent was used to generate aqueous foam in a separate foam generating system; the foam was then introduced into the slurry through the mixer); continuously depositing the slurry on a paper cover sheet (face paper) on a moving belt; placing another paper cover sheet (back paper) over the deposited slurry to form 'h.
- a laboratory test was run to demonstrate the effect of dead-burned magnesium oxide on the water resistance developer by a siloxane in a gypsum-based article.
- An emulsion was formed by mixing 0.7% of BS-94 siloxane and 550 grams of water in high shear mixer for 7500 rpm for 2.5 minutes. In tests 1-3, the emulsion was then mixed with 500 grams of calcined natural gypsum, 0.1 grams of CSA and a selected amount of Baymag 96 magnesium oxide in a Waring Blender for 10 seconds and formed into cubes which were heated overnight.
- Test 4 was run in the same manner except that a calcined synthetic gypsum was used. In all tests, 0.7% by weight of the siloxane was used.
- test 4 made with synthetic gypsum, absorbed less moisture than the sample of test 2 made with a natural gypsum, although the same amount of Baymag 96 was used in both tests.
- the difference is attributed to the impurities, such as fly ash, that are typically found in synthetic gypsums.
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- Curing Cements, Concrete, And Artificial Stone (AREA)
- Building Environments (AREA)
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PL05781059T PL1778457T3 (pl) | 2004-08-12 | 2005-07-25 | Metoda wytwarzania wodoodpornego wyrobu na bazie gipsu |
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US10/917,177 US7892472B2 (en) | 2004-08-12 | 2004-08-12 | Method of making water-resistant gypsum-based article |
PCT/US2005/026345 WO2006020369A2 (en) | 2004-08-12 | 2005-07-25 | Method of making water-resistant gypsum-based article |
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EP1778457A4 EP1778457A4 (en) | 2011-08-10 |
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US (1) | US7892472B2 (zh) |
EP (1) | EP1778457B1 (zh) |
JP (1) | JP5096147B2 (zh) |
KR (1) | KR101208469B1 (zh) |
CN (1) | CN101068677B (zh) |
AR (1) | AR051558A1 (zh) |
AU (1) | AU2005274131B2 (zh) |
CA (1) | CA2575455C (zh) |
CR (1) | CR8941A (zh) |
ES (1) | ES2563283T3 (zh) |
IL (1) | IL180945A (zh) |
MX (1) | MX2007001631A (zh) |
NO (1) | NO20070999L (zh) |
NZ (1) | NZ552840A (zh) |
PL (1) | PL1778457T3 (zh) |
RU (1) | RU2381902C2 (zh) |
SA (1) | SA05260252B1 (zh) |
UA (1) | UA86090C2 (zh) |
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EP3416923B1 (en) | 2016-02-19 | 2021-04-07 | Etex Building Performance International SAS | Gypsum board |
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US6144695A (en) * | 1997-12-23 | 2000-11-07 | At&T Corp. | Method and apparatus for reducing near-end crosstalk (NEXT) in discrete multi-tone modulator/demodulators |
FR2789679B1 (fr) * | 1999-02-12 | 2001-03-30 | Lafarge Platres | Element de construction prefabrique a base de platre, presentant une resistance a l'eau |
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US6770354B2 (en) * | 2001-04-19 | 2004-08-03 | G-P Gypsum Corporation | Mat-faced gypsum board |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3416923B1 (en) | 2016-02-19 | 2021-04-07 | Etex Building Performance International SAS | Gypsum board |
Also Published As
Publication number | Publication date |
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NO20070999L (no) | 2007-03-08 |
CN101068677B (zh) | 2010-05-05 |
JP2008509824A (ja) | 2008-04-03 |
CN101068677A (zh) | 2007-11-07 |
RU2007108551A (ru) | 2008-09-20 |
CA2575455A1 (en) | 2006-02-23 |
AU2005274131A1 (en) | 2006-02-23 |
MX2007001631A (es) | 2007-04-23 |
IL180945A0 (en) | 2007-07-04 |
JP5096147B2 (ja) | 2012-12-12 |
CA2575455C (en) | 2013-12-10 |
ES2563283T3 (es) | 2016-03-14 |
UA86090C2 (ru) | 2009-03-25 |
WO2006020369A3 (en) | 2007-07-05 |
EP1778457A4 (en) | 2011-08-10 |
ZA200700822B (en) | 2008-09-25 |
SA05260252B1 (ar) | 2008-02-25 |
US20060035112A1 (en) | 2006-02-16 |
AU2005274131B2 (en) | 2010-07-29 |
IL180945A (en) | 2014-03-31 |
KR20070050065A (ko) | 2007-05-14 |
PL1778457T3 (pl) | 2016-05-31 |
US7892472B2 (en) | 2011-02-22 |
KR101208469B1 (ko) | 2012-12-05 |
CR8941A (es) | 2010-02-09 |
EP1778457A2 (en) | 2007-05-02 |
RU2381902C2 (ru) | 2010-02-20 |
WO2006020369A2 (en) | 2006-02-23 |
AR051558A1 (es) | 2007-01-24 |
NZ552840A (en) | 2009-11-27 |
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